One-piece hat box insert



Jan.21, 1969 w. E. TURNER ETAL 1 ONE-PIECE HAT BOX INSERT Filed Dec. 6, 1967 I g i 1 I I I I a I 1 1 r I v I INVENTORS W/LL/AMEI TUAWEP GEO/965591650445 ORNEYS United States Patent 6 Claims ABSTRACT OF THE DISCLOSURE A one-piece paperboard insert for a hat box, comprising a horizontal main panel having a central opening; a pair of vertical spacer flaps hinged on opposed side edges of the main panel and disposed to lie against the walls of the box between the main panel and the top wall of the box; a tubular member disposed to extend vertically through said opening and comprising a pair of generally rectangular panels curved to fit the contour of said opening; and a pair of connecting flaps having inboard edges connected to respective panels and having outboard edges connected to corresponding side edges of said main panel.

This invention relates to the packaging of mens hats and more particularly to inserts which are used in connection with outer boxes.

In the past, inserts of this type have generally been formed of a plurality of pieces glued or stitched together. One conventional type of insert is a three-piece article consisting of a flanged platform, a steamed paper ring stitched to the inside of a paper oval, and a stitched circular sleeve to Support the platform.

It is the object of this invention to provide in a carton of the type described, a one-piece paperboard insert that may be readily formed and erected from a unitary blank of folded paperboard.

A more specific object of the invention is the provision, in an article of the type described, of an insert comprising a main horizontal panel with a central opening having a tubular member extending through the opening, which is formed from a pair of rectangular panels curved to fit the opening, and hingedly attached to the outer edges of the main panel by connecting flaps.

These and other objects of the invention will be apparent from an examination of the following description and drawing, wherein:

FIGURE 1 is a perspective view of an outer box of the type normally used for the packaging of mens hats;

FIGURE 2 is a transverse, vertical section taken on line 2-2 of FIGURE 1, illustrating the position of a hat and an insert embodying features of the invention, shown positioned within the outer box illustrated in FIGURE 1;

FIGURE 3 is an exploded perspective view, with portions of the structure broken away, illustrating the outer box and the insert;

FIGURE 4 is a plan view of the blank from which the insert illustrated in FIGURES 2 and 3 may be formed;

FIGURE 5 is a perspective view of the insert of the previous views shown in a partially erected condition; and

FIGURE 6 is a perspective view of an insert embodying a modified form of the invention.

It will be understood that, for purposes of clarity, certain elements have been intentionally omitted from certain views where they are believed to be illustrated to better advantage in other views.

Referring now to the drawing for a better understanding of the invention and particularly to FIGURE 3, it will be seen that the package for a hat is a composite package, indicated generally at 10, which includes an outer box 12 having a separate cover 14 and Within which is disposed a one-piece insert, indicated generally at 16, which may be formed from the unitary blank 18 of foldable paperboard illustrated in FIGURE 4 of the drawing.

Still referring to FIGURE 3, it will be seen that outer box 12 includes bottom wall 20 and a plurality of side walls 22 upstanding therefrom.

Cover 14 includes a top wall 24 and a plurality of side walls 26 depending therefrom which are adapted to telescope over upper portions of box side walls 22.

Still referring to FIGURE 3, it will be seen that the novel insert, embodying features of the invention and indicated generally at 16, includes a preferably rectangular or octagonal main panel 30 which is fiat and disposed within the box to extend horizontally with its side edges abutting the inside of the adjacent side walls of box 12.

Panel 30 is provided with a generally oval-shaped central opening 32 extending therethrough and adapted to receive a tubular member 40 which is described in detail later in the specification.

As best seen in FIGURE 4, a pair of spacer flaps 34 are hinged to the opposed end edges of main panel 30 on hinge lines 36. If the insert is to be adapted for use within an octagonal, rather than a square box, additional spacer flaps 35 may be formed from the corners of main panel 30 and hinged thereto on hinge lines 37. The purpose of the spacer flaps will be described later in the specification.

Still referring to FIGURES 3 and 4, it will be seen that there is positioned within central opening 32 of main panel 30 a tubular member indicated generally at 40. Tubular member 40 is preferably formed from a pair of general rectangular panels, each including a larger main section 42 and relatively narrow flange section 44 hingedly attached to the main section along a hinge line 46. When the carton is erected, the flange section will be folded outwardly and downwardly against the outer face of the related main section 42 and preferably adhesively secured thereto as at 48.

Each of the flange sections of the tubular member are connected to opposed side edges of main panel 30 by means of a connecting flap 50 which is hinged at one edge to a related side edge of panel 30 on a hinge line 52 and which is hinged at its other edge to the related lower edge of flange section 44 on a hinge line 56. In the erected condition, the connecting flap is preferably disposed to overlie the upper face of main panel 30 and be adhesively secured thereto as at 56.

In erecting the insert, the flange and main sections of each tubular insert panel are folded degrees about hinge line 54 so as to underlie the main panel 30. At this point, glue is applied from above and below to the surfaces 56 and 48 of the connecting flaps and flange sections, respectively. The entire tubular insert panel and related connecting flap 50, which are back-to-back at this time, are then folded in the opposite direction 180 degrees about hinge line 52 to bring the connecting flap into adhesive contact with the upper surface of main panel 30. Thereafter main section 42 is folded 180 degrees about hinge line 46 to bring the fiange section into adhesive contact with the outer surface of main section 42, as shown in FIGURE 5. At this point, the tubular section panels are forced downwardly through the central 3 opening 32 in the main panel, as shown in FIGURE 5 until they assume the vertical position and take on the contour of the central opening as shown in FIGURE 3.

After the inserts have been erected, they are inserted within the body 12 of the box, as shown in FIGURES 2 and 3 with the lower end of the tubular member resting on the bottom wall of the box. The hat to be packaged is then placed upside down in the box with the crown of the hat disposed to extend into the tubular member and with the brim Of the hat being supported on main panel 30 of the insert, which serves as a shelf around the periphery of the tubular member. Spacer flaps 34 and 35 are folded upwardly 90 degrees against the inner faces of related side walls of the outer box body. It will be seen that the height of the spacer flaps is equal to the distance between main panel 30 and the upper edge of the box side walls 22. When the cover 14 is placed over the box, the spacer flaps prevent the vertical movement of the insert within the box, and the engagement of the side edges of the panel with the related side walls of the box prevent the lateral movement of the insert within the box.

Thus, it will be seen that there is provided by the invention a unique, readily formable, one-piece paperboard insert which is of extremely simple design and construction and economical in cost.

We claim:

1. In a carton for packaging a hat with a crown and brim, an outer box having top, bottom and side walls, and a one-piece packing insert formed from a unitary blank of foldable paper board, said insert comprising:

(a) a horizontal main panel having an internal central opening for receiving a tubular member and having at least two pairs of opposed side edges disposed adjacent corresponding side walls of the outer box;

(b) a pair of vertical spacer flaps hinged to the side edges of one of said pairs and disposed to lie against inside surfaces of related outer box side walls and to extend upwardly between said main panel and an inside surface of the outer box top wall;

(c) a vertical tubular member, for receiving the crown of said hat, disposed to extend through the central opening of said main panel between the top and bottom walls of the outer box, with a major portion disposed below said main panel and a minor portion disposed above said main panel;

((1) said tubular member comprising a pair of generally rectangular panels curved to fit the contour of said central opening and each having hinged to its upper edge an outer flange which is folded against the outer surface thereof;

(e) a pair of connecting flaps overlying the upper surface of said main panel and having outer edges hinged to the side edges of the other said pairs and having inner edges hinged to lower edges of respective tubular member flanges.

2. In a carton for packaging a hat with a crown and brim, an outer box having top, bottom and side walls, and a one-piece packing insert formed from a unitary blank of foldable paper board, said insert comprising:

(a) a horizontal main panel having an internal central opening for receiving a tubular member and having at least two pairs of opposed side edges disposed adjacent corresponding side walls of the outer box;

(b) a pair of vertical spacer flaps hinged to the side edges of one of said pairs and disposed to lie against inside surfaces of related outer box side walls and to extend upwardly between said main panel and an inside surface of the outer box top Wall;

(c) a vertical tubular member, for receiving the crown of said hat, disposed to extend through the central opening of said main panel between the top and bottom walls of the outer box, with a major portion disposed below said main panel and a minor portion disposed above said main panel;

(d) said tubular member comprising at least one generally rectangular panel curved to fit the contour of said central opening and having hinged to its upper edge an outer flange which is folded against the outer surface thereof;

(e) a connecting flap disposed against said main panel and having an outer edge hinged to a side edge of one of the other of said pairs and having an inner edge hinged to a lower edge of said tubular member flange.

3. In a carton for packaging a hat with a crown and brim, an outer box having top, bottom and side walls, and a one-piece packing insert formed from a unitary blank of foldable paper board, said insert comprising:

(a) a horizontal main panel having an internal central opening for receiving a tubular member and having at least two pairs of opposed side edges disposed adjacent corresponding side walls of the outer box;

(b) a pair of vertical spacer flaps hinged to the side edges of one of said pairs and disposed to lie against inside surfaces of related outer box side walls and to extend upwardly between said main panel and an inside surface of the outer box top wall;

(c) a vertical tubular member, for receiving the crown of said hat, disposed to extend through the central opening of said main panel between the top and bottom walls of the outer box, with a major portion disposed below said main panel and a minor portion disposed above said main panel;

((1) said tubular member comprising at least one generally rectangular panel curved to fit the contour of said central opening;

(e) flap means hingedly connecting the panel of said tubular member to said main panel.

4. In a carton for packaging a'hat with a crown and brim, an outer box having top, bottom and side walls, and a one-piece packing insert formed from a unitary blank of foldable paperboard, said insert comprising:

(a) a horizontal main panel having an internal central opening for receiving a tubular member and having at least two pairs of opposed side edges. disposed adjacent corresponding side walls of the outer box;

(b) a vertical tubular member, for receiving the crown of said hat, disposed to extend through the central opening of said main panel between the top and bottom walls of the outer box, with a major portion disposed below said main panel and a minor portion disposed above said main panel;

(c) said tubular member comprising at least one generally rectangular panel curved to fit the contour of said central opening;

(d) flap means hingedly connecting the panel of said tubular member to said main panel.

5. A one-piece hat box insert formed from a unitary blank of foldable paperboard, comprising:

(a) a main horizontal panel having a central open- (b) a vertically disposed tubular member disposed to extend through said opening to the bottom of said hat box;

(0) at least one flap connecting said tubular member to said main panel.

6. In a carton for packaging a hat with a crown and brim, an outer box having top, bottom and side walls, and a one-piece packing insert formed from a unitary blank of foldable paperboard, said insert comprising:

(a) a horizontal main panel having an internal central opening for receiving a vertically disposed tubular member and having a peripheral ledge portion disposed adjacent a side wall of the outer box to prevent lateral movement of said main panel within said outer box;

(b) a tubular member, for receiving the crown of said 6 hat, vertically disposed to extend through the central ((1) flap means hingedly connecting the panel of said opening of said main panel between the top and bottubular member to said main panel.

tom walls of the outer box, with a major portion disposed below said main panel and a minor portion disposed above said main panel; UNITED STATES PATENTS (c) said tubular member comprising at least one gen- 5 2 794 543 6/1957 Shamberg erally rectangular panel curved to fit the contour of u said central opening; JAMES B. MARBERT, Primary Examiner.

References Cited 

